Ink Jet Recording Apparatus

ABSTRACT

An ink jet recording apparatus includes a recording head having a plurality of nozzles through which an ink composition containing an inorganic pigment is ejected, a nozzle surface having nozzle orifices, and a liquid-repellent film disposed on the nozzle surface; an absorbing member that absorbs the ink composition containing the inorganic pigment from the nozzle orifices and the nozzle surface; and an actuating mechanism including a pressing member that presses the absorbing member, which contains an impregnation liquid, and the nozzle surface relative to each other. The actuating mechanism moves at least one of the absorbing member and the recording head relative to the other to perform a cleaning operation in which the ink composition is removed from the nozzle surface with the absorbing member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/090,176, filed Nov. 26, 2013, which claims priority to JapaneseApplication No. 2012-262112 filed Nov. 30, 2012, both of which arehereby incorporated by reference in their entireties.

BACKGROUND 1. Technical Field

The present invention relates to ink jet recording apparatuses.

2. Related Art

In ink jet recording, ink droplets are propelled onto a recording mediumsuch as paper to produce a print. Recent revolutionary advances in inkjet recording technology have enabled the use of ink jet recordingapparatuses in the field of high-resolution image recording (imageprinting), where photography and offset printing have so far been used.

In an ink jet recording apparatus, ejected ink increases in viscosity(thickens) as water and other volatile components evaporate therefrom.Such thickened ink clogs nozzles, which causes problems with ejection ofink. In recent ink jet recording, ink droplets are ejected in extremelysmall amounts, i.e., several picoliters, for high-resolution recording.Accordingly, ink is ejected from smaller nozzles with lower energy.Because of the smaller nozzles and the lower ejection energy, nozzleclogging has a greater impact on ejection of ink. In addition, bubblesmay enter the nozzles and ink supply channels, which causes problemswith ejection. Furthermore, in ink jet recording on recording media suchas paper and fabric, large amounts of fiber and paper dust are producedduring paper feed operation. These substances, as well as ambient dustand extremely small ink droplets occurring during ejection, may bedeposited on a surface of an ink ejection print head in which nozzlesare formed (hereinafter referred to as “nozzle surface”). If foreignmatter such as ink, paper dust, fiber, and ambient dust is deposited onand around the nozzles, it blocks normal ejection of ink.

To reduce or eliminate problems with ejection due to ink thickening,entry of bubbles, and deposition of foreign matter on the nozzlesurface, ink jet recording apparatuses having a wiper mechanism(recovery mechanism) have been proposed.

For example, JP-A-2006-142804 discloses an ink jet recording apparatushaving a cleaning mechanism including a wiping blade. This referencediscloses that fine particles are distributed over the surface of thewiping blade to reduce the friction coefficient between the wiping bladeand the head, thereby protecting the nozzle surface.

As a compact, low-cost ink jet recording apparatus with highweatherability, durability, and reliability, JP-A-2009-101630 disclosesan ink jet recording apparatus including an applying unit that applies atreatment liquid to a recording head or a wiper member.

However, the wiping blade disclosed in JP-A-2006-142804 provides poorcleaning performance when used to clean a stepped nozzle surface.Specifically, when the wiping blade is used to clean a stepped nozzlesurface formed by a nozzle plate and a nozzle plate cover, the wipingblade is moved while scraping off ink outward from the center of theblade. Although the wiping blade leaves no ink near the nozzles, inkbuilds up around the wiping blade. In particular, scraped ink builds upat the step between the nozzle plate and the nozzle plate cover. Suchink build-up grows and eventually interferes with the lip surface of thecap, which prevents tight capping. For an ink jet recording apparatusconfigured for recording with an ink containing an inorganic pigment(hereinafter referred to as “inorganic-pigment containing inkcomposition”), simply using a treatment liquid as disclosed inJP-A-2009-101630 results in damage to a liquid-repellent film due to theinorganic pigment during cleaning and poor cleaning performance. Inaddition, the treatment liquid enters the nozzles together with bubblesand aggregates the pigment, which causes problems with ejection, and theliquid-repellent film cannot be sufficiently protected because thepressing force is not considered. Damage to the liquid-repellent filmresults in unstable ejection of ink, which causes problems such asirregular dot landing. FIG. 6A illustrates an example of an intactliquid-repellent film. FIG. 6B illustrates an example of a slightlydamaged liquid-repellent film, which does not significantly affectejection. FIG. 6C illustrates an example of a considerably damagedliquid-repellent film, which significantly affects ejection. Thecondition illustrated in FIG. 6C can result from repeated cleaningoperations under particular conditions with the use of an ink containingan inorganic pigment.

SUMMARY

An advantage of some aspects of the invention is that it provides an inkjet recording apparatus that allows both high cleaning performance andgood conservation of a liquid-repellent film in recording with aninorganic-pigment containing ink composition.

After conducting extensive research, the inventors have found that theuse of an absorbing member, such as fabric, that allows inorganicpigment particles to permeate into the absorbing member and thatcontains an impregnation liquid as a wiping member to clean (wipe) anozzle surface of an ink jet printer allows foreign matter such as inkmist, dust, and fabric fiber to be efficiently removed from the nozzlesurface, and the use of an ink composition containing a predeterminedinorganic pigment in a predetermined amount prevents inorganic pigmentparticles from damaging a liquid-repellent film on the nozzle surface.These findings have led to the invention.

(1) According to an aspect of the invention, there is provided an inkjet recording apparatus including a recording head having a plurality ofnozzles through which an ink composition containing an inorganic pigmentis ejected, a nozzle surface having nozzle orifices, and aliquid-repellent film disposed on the nozzle surface; an absorbingmember that absorbs the ink composition containing the inorganic pigmentfrom the nozzle orifices and the nozzle surface; and an actuatingmechanism including a pressing member that presses the absorbing memberand the nozzle surface relative to each other. The actuating mechanismmoves at least one of the absorbing member and the recording headrelative to the other to perform a cleaning operation in which the inkcomposition is removed from the nozzle surface with the absorbingmember. The absorbing member contains an impregnation liquid during thecleaning operation. The inorganic pigment is present in the inkcomposition in an amount of 20% by mass or less and has a Mohs hardnessof more than 2.0 and an average particle size of 200 nm or more.

(2) In Item (1), it is preferable that the impregnation liquid have asurface tension of 45 mN/m or less.

(3) In Item (1) or (2), it is preferable that the pressing member pressthe absorbing member containing the impregnation liquid against thenozzle surface with a force of 50 to 500 gf.

(4) In any one of Items (1) to (3), it is preferable that the actuatingmechanism move at least one of the absorbing member and the recordinghead relative to the other at a speed of 1 to 10 cm/s.

(5) In any one of Items (1) to (4), it is preferable that the recordinghead further have a nozzle plate cover that at least partially coversthe nozzle surface and that the absorbing member be a fabric.

(6) In any one of Items (1) to (5), it is preferable that the absorbingmember have a thickness of 0.1 to 3 mm.

(7) In any one of Items (1) to (6), it is preferable that the ink jetrecording apparatus further include an elastic member that covers thepressing member and that has a Shore A hardness of 10 to 60.

(8) In any one of Items (1) to (7), it is preferable that the inkcomposition further contain a resin emulsion.

(9) In any one of Items (1) to (8), it is preferable that the nozzlesurface have a first row of nozzles through which the ink compositioncontaining the inorganic pigment is ejected and a second row of nozzlesthrough which an ink composition containing a colorant other than theinorganic pigment is ejected and that the actuating mechanism move atleast one of the absorbing member and the recording head relative to theother in a direction in which the nozzles are arranged.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described with reference to the accompanyingdrawings, wherein like numbers reference like elements.

FIG. 1 is a perspective view of an ink jet recording apparatus accordingto an embodiment of the invention.

FIG. 2 is a perspective view of a wiper unit.

FIG. 3A is a front view of a wiper cassette.

FIG. 3B is a front view of the wiper cassette, with a housing omitted.

FIG. 4 is a reference view illustrating ink build-up in a cleaningperformance test.

FIGS. 5A and 5B illustrate a nozzle surface.

FIGS. 6A to 6C are light micrographs of areas surrounding nozzles aftercleaning.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the invention will now be described in detail. Theinvention, however, is not limited to these embodiments; variousmodifications are possible without departing from the spirit of theinvention.

Ink Jet Recording Apparatus

An ink jet recording apparatus according to an embodiment of theinvention includes a recording head, an absorbing member, and anactuating mechanism. The recording head has a plurality of nozzlesthrough which an ink composition containing an inorganic pigment isejected, a nozzle surface having nozzle orifices, and a liquid-repellentfilm disposed on the nozzle surface. The absorbing member absorbs theink composition containing the inorganic pigment from the nozzleorifices and the nozzle surface. The actuating mechanism includes apressing member that presses the absorbing member and the nozzle surfacerelative to each other. The actuating mechanism moves at least one ofthe absorbing member and the recording head relative to the other toperform a cleaning operation in which the ink composition is removedfrom the nozzle surface with the absorbing member. The absorbing membercontains an impregnation liquid during the cleaning operation. Theinorganic pigment is present in the ink composition in an amount of 20%by mass or less and has a Mohs hardness of more than 2.0 and an averageparticle size of 200 nm or more.

1. Structure of Apparatus 1-1. Recording Head

The recording head according to this embodiment has a nozzle surfacehaving a plurality of nozzles through which an inorganic-pigmentcontaining ink composition is ejected and a liquid-repellent filmdisposed on the nozzle surface.

Nozzle Surface

The nozzle surface may be any surface having a plurality of nozzlesthrough which an inorganic-pigment containing ink composition isejected. The nozzle surface may have a first row of nozzles throughwhich the inorganic-pigment containing ink composition is ejected and asecond row of nozzles through which an ink composition containing acolorant other than inorganic pigments (hereinafter referred to as“inorganic-pigment-free ink composition”) is ejected. In this case, itis preferable that the actuating mechanism, described later, move atleast one of the absorbing member and the recording head relative to theother in the direction in which the nozzles are arranged in rows andthat the first and second rows of nozzles be cleaned with differentportions of the absorbing member. This prevents the second row ofnozzles from being cleaned with a portion of the absorbing member onwhich the inorganic-pigment containing ink composition ejected from thefirst row of nozzles is deposited. Thus, the inorganic pigment, whichtends to degrade the liquid-repellent film, does not spread to thesecond row of nozzles and degrade the liquid-repellent film near thesecond row of nozzles. That is, the liquid-repellent film is notextensively degraded. In the cleaning operation, the second row ofnozzles may be cleaned after the first row of nozzles is cleaned, or thetwo rows of nozzles may be simultaneously cleaned. Preferably, the tworows of nozzles are simultaneously cleaned for increased cleaningefficiency.

Liquid-Repellent Film

The liquid-repellent film is disposed on the nozzle surface. Theliquid-repellent film may be any film with liquid repellency. Forexample, the liquid-repellent film may be formed by depositing, drying,and annealing a metal alkoxide molecular film with liquid repellency.The metal alkoxide molecular film may be any metal alkoxide molecularfilm with liquid repellency. Preferably, the metal alkoxide molecularfilm is a monomolecular film of a metal alkoxide having afluorine-containing long-chain polymer group (long-chain RF group) or amonomolecular film of a metal acid salt having a liquid-repellent group(e.g., a fluorine-containing long-chain polymer group). Typical examplesof metals in such metal alkoxides include, but not limited to, silicon,titanium, aluminum, and zirconium. Examples of long-chain RF groupsinclude perfluoroalkyl chains and perfluoropolyether chains. Examples ofalkoxysilanes having a long-chain RF group include silane couplingagents (SCAs) having a long-chain RF group. Examples of liquid-repellentfilms include, but not limited to, SCA films and those disclosed inJapanese Patent No. 4424954. In particular, films with water repellencyare referred to as “water-repellent film”.

The liquid-repellent film may be formed on a conductive film formed on asubstrate having nozzles (nozzle plate). Alternatively, theliquid-repellent film may be formed on an underlayer deposited by plasmapolymerization of a material for silicone (plasma polymerizationsilicone (PPSi) film). This underlayer increases the compatibilitybetween the nozzle plate and the liquid-repellent film.

The liquid-repellent film preferably has a thickness of 1 to 30 nm, morepreferably 1 to 20 nm, even more preferably 1 to 15 nm. Such aliquid-repellent film tends to make the nozzle surface moreliquid-repellent and maintains liquid repellency over a longer period oftime because of its relatively slow degradation. In addition, such aliquid-repellent film can be formed more easily and at a lower cost.

Nozzle Plate Cover

A nozzle plate cover is preferably disposed on the nozzle surface so asto at least partially cover the nozzle surface. The nozzle plate coveris intended to provide at least one of the function of holding aplurality of nozzle chips (hereinafter simply referred to as “chips”),which are combined to form the nozzle surface of the recording head, andthe function of preventing a recording medium from coming into directcontact with the nozzles when the recording medium rises. The nozzleplate cover at least partially covers the nozzle surface so as toprotrude from the nozzle surface in a side view. If the nozzle platecover is provided, the inorganic-pigment containing ink compositiontends to remain at the corner (gap) between the nozzle surface and thenozzle plate cover protruding therefrom. Solidification of the inorganicpigment contained in the remaining inorganic-pigment containing inkcomposition results in a loose contact between the cap and the nozzlesurface, which can cause problems with capping operation. This problemcan be particularly noticeable depending on the type of resin containedin the ink composition. Accordingly, the absorbing member containing theimpregnation liquid is brought into contact with the corner between thenozzle plate cover and the nozzle surface to remove theinorganic-pigment containing ink composition therefrom. This stabilizesthe capping operation.

FIGS. 5A and 5B are schematic views of a nozzle surface 37 of the inkjet recording apparatus according to this embodiment. Examples ofpatterns in which the nozzle plate cover 35 is provided on the nozzlesurface 37 include, but not limited to, a pattern in which the nozzleplate cover 35 is provided around each nozzle row 36 (the nozzle platecover 35 is also provided between the nozzle rows 36), as shown in FIG.5A, and a pattern in which the nozzle plate cover 35 is provided aroundthe entire region in which the nozzles are arranged (the nozzle platecover 35 is not provided between the nozzle rows 36), as shown in FIG.5B. In FIGS. 5A and 5B, the circles in the nozzle rows 36 represent thenozzles.

1-2. Absorbing Member

The absorbing member according to this embodiment may be any member thatcan absorb the inorganic-pigment containing ink composition from thenozzle orifices and the nozzle surface and that can contain theimpregnation liquid. When the nozzle surface is cleaned, such anabsorbing member absorbs the pigment particles and leaves no pigmentparticles on the surface thereof. This reduces damage to theliquid-repellent film due to the pigment particles.

Examples of absorbing members include, but not limited to, fabrics,sponges, and pulps. In particular, fabrics are preferred because theyare flexible and easily wipe ink off the nozzle surface, particularly ifthe nozzle plate cover is provided. Examples of fabrics include cupra,polyester, polyethylene, polypropylene, lyocell, and rayon. Inparticular, nonwoven fabrics (polyester) and cupra are preferred for theabsorbing member because they are resistant to fuzzing so that theyabsorb less ink from the nozzles and thus cause fewer missing dots.

The absorbing member preferably has a thickness of 0.1 to 3 mm. If theabsorbing member has a thickness of 0.1 mm or more, the absorbing membercan contain more impregnation liquid. If the absorbing member has athickness of 3 mm or less, the absorbing member is compact, whichcontributes to a reduction in the overall size of the cleaning unit andalso facilitates mechanical transportation of the cleaning member.

The absorbing member preferably has an area density of 0.005 to 0.15g/cm², more preferably 0.02 to 0.13 g/cm². Such an absorbing member cancontain more impregnation liquid. The absorbing member is preferablymade of a fabric whose area density and thickness can be easilycontrolled so that it can contain more impregnation liquid.

Impregnation Liquid

The absorbing member contains an impregnation liquid during the cleaningoperation. The impregnation liquid facilitates movement of the pigmentparticles from the surface of the absorbing member into the interiorthereof, leaving fewer pigment particles on the surface of the absorbingmember. The impregnation liquid preferably contains a penetrant and ahumectant. This facilitates absorption of the pigment particles into theabsorbing member. The impregnation liquid may be any liquid that allowsthe inorganic pigment particles to move from the surface of theabsorbing member into the interior thereof. The impregnation liquid maybe contained in the absorbing member in advance or may be applied to theabsorbing member when the cleaning operation is performed.

The impregnation liquid preferably has a surface tension of 45 mN/m orless, more preferably 35 mN/m or less. A lower surface tension resultsin a higher permeability of the inorganic pigment into the absorbingmember and thus a higher wiping performance. The surface tension may bemeasured, for example, by the Wilhelmy method at a liquid temperature of25° C. using a commonly used surface tension meter (e.g., a CBVP-Zsurface tension meter available from Kyowa Interface Science Co., Ltd.).

The impregnation liquid is preferably present in an amount of 10% to200% by mass, more preferably 10% to 120% by mass, even more preferably30% to 100% by mass, based on 100% by mass of the absorbing member. Ifthe impregnation liquid is present in an amount of 10% by mass or more,the inorganic pigment ink can easily permeate into the absorbing memberand thus causes less damage to the liquid-repellent film. If theimpregnation liquid is present in an amount of 200% by mass or less,less impregnation liquid remains on the nozzle surface. This results infewer missing dots due to entry of bubbles into the nozzles togetherwith the impregnation liquid and entry of the impregnation liquid itselfinto the nozzles.

Examples of other additives (components) that can be contained in theimpregnation liquid include, but not limited to, resins, defoamers,surfactants, water, organic solvents, and pH adjusters. These componentsmay be used alone or in combination and may be present in any amount.

If the impregnation liquid contains a defoamer, the defoamer effectivelyprevents foaming of the impregnation liquid remaining on the nozzlesurface after cleaning. In some cases, the impregnation liquid containsa large amount of acidic humectant such as polyethylene glycol orglycerol. In such cases, if the impregnation liquid contains a pHadjuster, the pH adjuster avoids contact of an acidic impregnationliquid with the ink composition (which is typically basic, i.e., pH 7.5or higher). This prevents the ink composition from shifting to the acidside, thus improving the storage stability of the ink composition.

The humectant that can be contained in the impregnation liquid may beany humectant that can be commonly used with materials such as inks. Thehumectant is preferably, but not limited to, a high-boiling-pointhumectant having a boiling point at 1 atmosphere of 180° C. or higher,more preferably 200° C. or higher. A humectant having such a boilingpoint prevents volatilization of volatile components from theimpregnation liquid. This allows the impregnation liquid to reliablycontact and wet the inorganic-pigment containing ink composition so thatit can be effectively wiped.

Examples of high-boiling-point humectants include, but not limited to,ethylene glycol, propylene glycol, diethylene glycol, triethyleneglycol, pentamethylene glycol, trimethylene glycol, 2-butene-1,4-diol,2-ethyl-1,3-hexanediol, 2-methyl-2,4-pentanediol, tripropylene glycol,polyethylene glycol, polypropylene glycol, 1,3-propylene glycol,isopropylene glycol, isobutylene glycol, glycerol, mesoerythritol, andpentaerythritol.

These humectants may be used alone or in combination. The humectant ispreferably present in an amount of 10% to 100% by mass based on thetotal mass (100% by mass) of the impregnation liquid. The case where thehumectant is present in an amount of 100% by mass based on the totalmass of the impregnation liquid means that the impregnation liquid iscomposed only of the humectant.

Among the additives that can be contained in the impregnation liquid,penetrants will be described. The impregnation liquid may contain anypenetrant that can be commonly used with materials such as inks. Thepenetrant may be a solution containing 90% by mass of water and 10% bymass of a penetrant and having a surface tension of 45 mN/m or less. Thepenetrant may be, for example, but not limited to, at least onepenetrant selected from the group consisting of alkanediols having 5 to8 carbon atoms, glycol ethers, acetylene glycol surfactants, siloxanesurfactants, and fluorinated surfactants. The surface tension may bemeasured by the method described above.

The penetrant is preferably present in the impregnation liquid in anamount of 1% to 40% by mass, more preferably 3% to 25% by mass. If thepenetrant is present in an amount of 1% by mass or more, theimpregnation liquid tends to provide a higher wipeability. If thepenetrant is present in an amount of 40% by mass or less, the penetrantdoes not attack the pigment contained in the ink near the nozzles andcause aggregation due to decreased dispersion stability.

Examples of alkanediols having 5 to 8 carbon atoms include, but notlimited to, 1,2-pentanediol, 1,5-pentanediol, 1,2-hexanediol,1,6-hexanediol, 1,2-heptanediol, 2-ethyl-1,3-hexanediol,2,2-dimethyl-1,3-propanediol, and 2,2-dimethyl-1,3-hexanediol. Thesealkanediols having 5 to 8 carbon atoms may be used alone or incombination.

Examples of glycol ethers include, but not limited to, ethylene glycolmono-n-butyl ether, ethylene glycol mono-t-butyl ether, diethyleneglycol mono-n-butyl ether, triethylene glycol mono-n-butyl ether,diethylene glycol mono-t-butyl ether, propylene glycol monomethyl ether,propylene glycol monoethyl ether, propylene glycol mono-t-butyl ether,propylene glycol mono-n-propyl ether, propylene glycol monoisopropylether, propylene glycol mono-n-butyl ether, dipropylene glycolmono-n-butyl ether, dipropylene glycol mono-n-propyl ether, dipropyleneglycol monoisopropyl ether, diethylene glycol dimethyl ether, diethyleneglycol diethyl ether, diethylene glycol dibutyl ether, diethylene glycolethyl methyl ether, diethylene glycol butyl methyl ether, triethyleneglycol dimethyl ether, tetraethylene glycol dimethyl ether, dipropyleneglycol dimethyl ether, dipropylene glycol diethyl ether, tripropyleneglycol dimethyl ether, ethylene glycol monoisohexyl ether, diethyleneglycol monoisohexyl ether, triethylene glycol monoisohexyl ether,ethylene glycol monoisoheptyl ether, diethylene glycol monoisoheptylether, triethylene glycol monoisoheptyl ether, ethylene glycolmonoisooctyl ether, diethylene glycol monoisooctyl ether, triethyleneglycol monoisooctyl ether, ethylene glycol mono-2-ethylhexyl ether,diethylene glycol mono-2-ethylhexyl ether, triethylene glycolmono-2-ethylhexyl ether, diethylene glycol mono-2-ethylpentyl ether,ethylene glycol mono-2-ethylpentyl ether, ethylene glycolmono-2-methylpentyl ether, and diethylene glycol mono-2-methylpentylether. These glycol ethers may be used alone or in combination.

Examples of acetylene glycol surfactants include, but not limited to,compounds represented by the following formula:

(where 0 m+n≤50 and R¹*, R²*, R³*, and R⁴* are each independently analkyl group (preferably, an alkyl group having 1 to 6 carbon atoms)).

Preferred acetylene glycol surfactants represented by formula (1)include 2,4,7,9-tetramethyl-5-decyne-4,7-diol,3,6-dimethyl-4-octyne-3,6-diol, and 3,5-dimethyl-1-hexyn-3-ol.Commercial products of acetylene glycol surfactants represented byformula (1) are also available, including Surfynol 82, 104, 440, 465,485, and TG (all available from Air Products and Chemicals, Inc.) andOlfine STG and Olfine E1010 (trade names, available from Nissin ChemicalIndustry Co., Ltd.). These acetylene glycol surfactants may be usedalone or in combination.

Examples of siloxane surfactants include, but not limited to, compoundsrepresented by the following formula:

(where R¹, R², R³, R⁴, R⁵, R⁶, and R⁷ are each independently an alkylgroup having 1 to 6 carbon atoms, preferably methyl; j and k are eachindependently an integer of 1 or more, preferably 1 to 5, morepreferably 1 to 4, even more preferably 1 or 2, where it is preferableto satisfy j=k=1 or k=j+1; g is an integer of 0 or more, preferably 1 to3, more preferably 1; and p and q are each an integer of 0 or more,preferably 1 to 5, where p+q is an integer of 1 or more, preferably 2 to4).

Preferred siloxane surfactants represented by formula (2) includecompounds where R⁴ to R⁷ are all methyl, j is 1 or 2, k is 1 or 2, g is1 or 2, p is an integer of 1 to 5, and q is 0.

Examples of siloxane surfactants also include compounds represented bythe following formula:

(where R is hydrogen or methyl, a is an integer of 2 to 18, m is aninteger of 0 to 50, and n is an integer of 1 to 5).

Preferred siloxane surfactants represented by formula (3) include, butnot limited to, compounds where R is hydrogen or methyl, a is an integerof 7 to 11, m is an integer of 30 to 50, and n is an integer of 3 to 5;compounds where R is hydrogen or methyl, a is an integer of 9 to 13, mis an integer of 2 to 4, and n is an integer of 1 or 2; compounds whereR is hydrogen or methyl, a is an integer of 6 to 18, m is 0, and n is 1;and compounds where R is hydrogen, a is an integer of 2 to 5, m is aninteger of 20 to 40, and n is an integer of 3 to 5.

Commercially available siloxane surfactants may also be used, includingOlfine PD-501 (available from Nissin Chemical Industry Co., Ltd.),Olfine PD-570 (available from Nissin Chemical Industry Co., Ltd.),BYK-347 (available from BYK Japan KK), and BYK-348 (available from BYKJapan KK). The above siloxane surfactants may be used alone or incombination.

As disclosed in WO2010/050618 and WO2011/007888, fluorinated surfactantsare known to have good wettability on recoding media that absorb littleor no ink. Examples of fluorinated surfactants include, but not limitedto, perfluoroalkylsulfonic acid salts, perfluoroalkylcarboxylic acidsalts, perfluoroalkylphosphoric acid esters, perfluoroalkyl ethyleneoxide adducts, perfluoroalkyl betaines, and perfluoroalkylamine oxides,any of which may be selected depending on the purpose.

Specially synthesized fluorinated surfactants and commercially availablefluorinated surfactants may also be used. Examples of commerciallyavailable fluorinated surfactants include S-144 and S-145 (availablefrom Asahi Glass Co., Ltd.); FC-170C, FC-430, and FLUORAD FC-4430(available from Sumitomo 3M Limited); FSO, FSO-100, FSN, FSN-100, andFS-300 (available from Dupont); and FT-250 and FT-251 (available fromNEOS Co, Ltd.). Particularly preferred are FSO, FSO-100, FSN, FSN-100,and FS-300 available from Dupont. These fluorinated surfactants may beused alone or in combination.

1-3. Actuating Mechanism

The actuating mechanism according to this embodiment moves at least oneof the absorbing member and the recording head relative to the other toperform a cleaning operation in which the ink composition is removedfrom the nozzle surface with the absorbing member. The actuatingmechanism preferably includes a pressing member that presses theabsorbing member containing the impregnation liquid and the nozzlesurface relative to each other with a force of 50 to 500 gf, morepreferably 75 to 300 gf. A pressing force of 50 gf or more provides highink wipeability. In addition, if there is a step between the nozzleplate and the nozzle plate cover, such a pressing force is effective inpreventing ink from being deposited in the gap therebetween or removingink therefrom. A pressing force of 500 gf or less allows a betterconservation of the liquid-repellent film. The actuating mechanism maybe configured in any manner. For example, the actuating mechanism may beconfigured to bring the absorbing member into contact with the nozzlesurface by pressing the side of the absorbing member facing away fromthe nozzle surface. Alternatively, the actuating mechanism may beconfigured to bring the absorbing member into contact with the nozzlesurface by actuating the recording head. As used herein, the term “load”refers to the total load applied to the nozzle surface by the entireactuating mechanism.

The actuating mechanism preferably moves the absorbing member and therecording head relative to each other at a speed of 1 to 10 cm/s. Such aspeed further improves the cleaning performance and the conservation ofthe liquid-repellent film. The speed of the cleaning operation isgenerally, but not limited to, about one fifth to one twentieth thetypical speed at which the recording head moves during image recording.

The pressing member is preferably, but not necessarily, covered with,for example, an elastic member. The elastic member preferably has aShore A hardness of 10 to 60, more preferably 10 to 50. This allows thepressing member and the absorbing member to be bent when pressed so thatthe absorbing member can be pressed further into a step in the nozzlesurface. In particular, if the nozzle plate cover is provided, theabsorbing member can be pressed further into the corner (gap) betweenthe nozzle surface and the nozzle plate protruding therefrom for reducedink build-up. This further improves the cleaning performance.

2. Operation of Apparatus

FIG. 1 is a perspective view of the ink jet recording apparatusaccording to this embodiment. FIG. 2 is a perspective view of a wiperunit. FIG. 3A is a front view of a wiper cassette. FIG. 3B is a frontview of the wiper cassette, with a housing omitted. The ink jetrecording apparatus illustrated in FIGS. 1 to 3B is configured asdescribed above. The operation of the ink jet recording apparatus willnow be described in detail. As shown in FIG. 1, a head maintenancedevice 26 for maintenance of a recording head 22 is disposed at a homeposition HP to the right of a recording region in which recording paperP is transported in a frame 12.

The head maintenance device 26 includes a wiper unit 34 including awiper cassette 31 carrying an absorbing member 30 that wipes ink off thenozzle surface of the recording head 22, a wiper holder 32 to which thewiper cassette 31 is removably attached, and a moving mechanism 33 thatmoves the wiper holder 32 in the nozzle row direction of the recordinghead 22 (the transport direction of the recording paper P in FIG. 1). Inaddition to the wiper unit 34, the head maintenance device 26 mayinclude a cap (not shown) that can be brought into contact with thenozzle surface of the recording head 22 so as to cover the nozzles and asuction pump (not shown) that is driven to remove and discharge wasteink, such as thickened ink, from the recording head 22 through the cap.The actuating mechanism according to this embodiment, which presses theabsorbing member containing the impregnation liquid against the nozzlesurface, includes at least a pressing member 87 and bar springs 90 (seeFIG. 3A) and may also include the moving mechanism 33.

As shown in FIGS. 3A and 3B, a substantially rectangular housing 80forms the exterior of the wiper cassette 31. The housing 80 accommodatesa pair of rollers 81 and 82 having the axes thereof extendinghorizontally in the lateral direction of the housing 80, i.e., thefront-to-rear direction. The pair of rollers 81 and 82 are disposed at adistance in the longitudinal direction of the housing 80, i.e., theleft-to-right direction. A long absorbing member 30 is entrained aboutthe pair of rollers 81 and 82 to wipe ink off the nozzle surface of therecording head 22. Of the pair of rollers 81 and 82, the roller 81 is afeed roller disposed as a first roller. The feed roller 81 feeds anunused absorbing member 30 wound therearound. The takeup roller 82collects the absorbing member 30 fed from the feed roller 81 and usedfor wiping. The feed roller 81 and the takeup roller 82 are locatedsubstantially at the same height. A feed gear is disposed at an end(front end) of the feed roller 81 exposed outside the housing 80 in theaxial direction so as to be rotatable together with the feed roller 81.Takeup gears 84 and 85 are disposed at both ends of the takeup roller 82exposed outside the housing 80 in the axial direction so as to berotatable together with the takeup roller 82.

In the housing 80, a plurality of (in this embodiment, four) rollers 86,88, 89, and 92 and the pressing member 87 are arranged along the feedpath of the absorbing member 30 from the feed roller 81 to the takeuproller 82. The rollers 86, 88, 89, and 92 and the pressing member 87extend parallel to the feed roller 81 and the takeup roller 82 in thefront-to-rear direction and are rotatably supported at both ends in thefront-to-rear direction, for example, by bearing portions provided inthe sidewalls of the housing 80.

Specifically, the portion of the absorbing member fed from the feedroller 81 is entrained about the pressing member 87, which is disposedto the upper left of the feed roller 81. Shafts 87 a at both ends of thepressing member 87 in the axial direction are supported from below bythe bar springs 90, which are fixed to the outer surfaces in the frontand rear of the housing 80. The bar springs 90 support the shafts 87 aof the pressing member 87 from below midway along the length thereof.The shafts 87 a of the pressing member 87 are inserted in bearing holes91 provided in the housing 80 in the front-to-rear direction and arebrought into close contact with the upper edges of the bearing holes 91by an upward biasing force exerted by the bar springs 90. The shafts 87a of the pressing member 87 are rotatably supported from above and belowbetween the bar springs 90 and the edges of the bearing holes 91. Thetop of the circumferential surface of the pressing member 87 is locatedabove the top surface of the housing 80. The portion of the absorbingmember 30 entrained about the pressing member 87 protrudes above the topsurface of the housing 80. The top of the circumferential surface of thepressing member 87 is also located above the nozzle surface of therecording head 22.

The actuating mechanism according to this embodiment, which includes atleast the bar springs 90 and the pressing member 87, can press theabsorbing member 30 containing the impregnation liquid against thenozzle surface with the upward biasing force exerted by the bar springs90 to apply a pressing load to the nozzle surface. The pressing load inthis embodiment is a spring load. The mechanism that applies thepressing load may be any mechanism that can press the absorbing member30 against the nozzle surface at a certain load. For example, mechanismsother than springs may be used, including rubber. Instead of using suchmechanisms, the pressing load may be applied, for example, byelectrically controlling a mechanical element.

The roller 89 is a relay roller disposed vertically below the pressingmember 87. The portion of the absorbing member 30 fed from the pressingmember 87 is entrained about the relay roller 89. The roller 92 is apinch roller disposed opposite the relay roller 89 with the absorbingmember 30 therebetween. The absorbing member 30 is pinched between therelay roller 89 and the pinch roller 92. A spring member 93 acting as abiasing member is disposed between the inner surface of the bottom wallof the housing 80 and the pinch roller 92. The spring member 93 biasesthe pinch roller 92 toward the relay roller 89.

A relay gear 94 is disposed at an end, exposed outside the sidewall ofthe housing 80, of a shaft 89 a at one end of the relay roller 89 in theaxial direction so as to be rotatable together with the relay roller 89.Shafts 92 a at both ends of the pinch roller 92 in the axial directionhave the ends thereof exposed outside cutout bearing portions 91 formedwhen elastic tabs are formed by cutting the sidewalls of the housing 80.

The rollers 86 and 88 are tension rollers that tension the absorbingmember 30. The tension roller 86 is disposed between the feed roller 81and the pressing member 87 along the feed path of the absorbing member30 from the feed roller 81 to the takeup roller 82. The tension roller88 is disposed between the pressing member 87 and the relay roller 89along the feed path of the absorbing member 30 from the feed roller 81to the takeup roller 82. Shafts 86 a and 88 a at both ends of thetension rollers 86 and 88, respectively, in the axial direction have theends thereof exposed outside circular bearing portions provided in thesidewalls of the housing 80.

Ink Composition

The ink jet recording apparatus according to this embodiment may be anytype of ink jet recording apparatus having nozzles through which aninorganic-pigment containing ink composition is ejected and may alsohave nozzles through which an inorganic-pigment-free ink composition isejected. The additives (components) that are, or can be, contained inthe inorganic-pigment containing ink composition and theinorganic-pigment-free ink composition according to this embodiment(hereinafter collectively referred to as “ink composition”) will now bedescribed.

1. Colorant

The inorganic-pigment containing ink composition according to thisembodiment may be any ink composition that contains an inorganicpigment. The inorganic-pigment-free ink composition may contain acolorant. The colorant is selected from pigments other than inorganicpigments and dyes.

1-1. Pigment

Examples of inorganic pigments include, but not limited to, carbonblack, iron oxide, titanium oxide, and silica.

The inorganic pigment contained in the inorganic-pigment containing inkcomposition has an average particle size of 200 nm or more, preferably250 nm or more. The average particle size is preferably up to 4 μm, morepreferably up to 2 μm. The inorganic pigment has a Mohs hardness of morethan 2.0, preferably 5 or more. The Mohs hardness is preferably up to 8.Such an inorganic pigment relatively easily damages the liquid-repellentfilm, thus resulting in poor conservation of the liquid-repellent filmin a common ink jet recording apparatus. However, even if such aninorganic pigment is used, the ink jet recording apparatus according tothis embodiment, configured as described above, allows good conservationof the liquid-repellent film. The use of an organic pigment tends to beless likely to result in poor conservation of the liquid-repellent filmthan the use of an inorganic pigment because a typical organic pigmenthas a Mohs hardness of not more than 1.

The inorganic-pigment containing ink composition contains the inorganicpigment in an amount of 20% by mass or less. Particularly, if theinorganic-pigment containing ink composition is a white ink composition,it preferably contains the inorganic pigment in an amount of 5% by massor more. Such an ink composition tends to have the properties requiredof an inorganic pigment ink while allowing good conservation of theliquid-repellent film in the ink jet recording apparatus according tothis embodiment.

The Mohs hardness is measured with a Mohs hardness tester. Devised by F.Mohs, the Mohs hardness tester uses ten types of minerals, ranging fromsoft to hard minerals, that are contained in boxes and that are numberedfrom 1 to 10 in ascending order of hardness to indicate the order ofhardness. The standard minerals are as follows (the numbers indicatehardness): talc (1), gypsum (2), calcite (3), fluorite (4), apatite (5),orthoclase (6), quartz (7), topaz (8), corundum (9), and diamond (10).The hardness can be compared by scratching the surface of a mineralsample of interest with the standard minerals to determine theresistance to scratching (whether the sample is scratched). For example,if the sample scratches calcite, the sample has a hardness of more than3. If fluorite scratches the sample but the sample does not scratchfluorite, the sample has a hardness of less than 4. In this case, thehardness of the sample is rated as 3 to 4, or 3.5. If the sample and anystandard sample slightly scratch each other, the sample has the samehardness rating as the standard sample used. The hardness measured withthe Mohs hardness tester is merely an ordinal rank and not an absolutevalue.

Examples of inorganic pigments having a Mohs hardness of more than 2.0include, but not limited to, elemental metals such as gold, silver,copper, aluminum, nickel, and zinc; oxides such as cerium oxide,chromium oxide, aluminum oxide, zinc oxide, magnesium oxide, siliconoxide, tin oxide, zirconium oxide, iron oxide, and titanium oxide;sulfates such as calcium sulfate, barium sulfate, and aluminum sulfate;silicates such as calcium silicate and magnesium silicate; nitrides suchas boron nitride and titanium nitride; carbides such as silicon carbide,titanium carbide, boron carbide, tungsten carbide, and zirconiumcarbide; and borides such as zirconium boride and titanium boride.Particularly preferred are aluminum, aluminum oxide, titanium oxide,zinc oxide, zirconium oxide, and silicon oxide, more preferably titaniumoxide, silicon oxide, and aluminum oxide. Titanium oxides includerutile-type titanium oxide, which has a Mohs hardness of about 7 to 7.5,and anatase-type titanium oxide, which has a Mohs hardness of about 5.5to 6. Rutile-type titanium oxide is a preferred crystal system with highwhiteness and low manufacturing cost. With rutile-type titanium dioxide,the ink jet recording apparatus can produce a print with high whitenessat low cost while allowing good conservation of the liquid-repellentfilm.

Examples of white inorganic pigments include alkaline earth metalsulfates such as barium sulfate; alkaline earth metal carbonates such ascalcium carbonate; silicas such as pulverized silica and syntheticsilica; metal compounds such as calcium silicate, alumina, hydratedalumina, titanium oxide, and zinc oxide; and other inorganic pigmentssuch as talc and clay. Particularly, titanium oxide is known as a whitepigment with suitable opacity, coloring properties, and dispersedparticle size.

Examples of organic pigments include, but not limited to, quinacridonepigments, quinacridonequinone pigments, dioxazine pigments,phthalocyanine pigments, anthrapyrimidine pigments, anthanthronepigments, indanthrone pigments, flavanthrone pigments, perylenepigments, diketopyrrolopyrrole pigments, perinone pigments,quinophthalone pigments, anthraquinone pigments, thioindigo pigments,benzimidazolone pigments, isoindolinone pigments, azomethine pigments,and azo pigments. Specific examples of organic pigments are as follows.

Examples of pigments used for cyan inks include C.I. Pigment Blue 1, 2,3, 15, 15:1, 15:2, 15:3, 15:4, 15:6, 15:34, 16, 18, 22, 60, 65, and 66and C.I. Vat Blue 4 and 60. Particularly preferred is at least one ofC.I. Pigment Blue 15:3 and 15:4.

Examples of pigments used for magenta inks include C.I. Pigment Red 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, 15, 16, 17, 18, 19, 21, 22, 23,30, 31, 32, 37, 38, 40, 41, 42, 48 (Ca), 48 (Mn), 57 (Ca), 57:1, 88,112, 114, 122, 123, 144, 146, 149, 150, 166, 168, 170, 171, 175, 176,177, 178, 179, 184, 185, 187, 202, 209, 219, 224, 245, 254, and 264 andC.I. Pigment Violet 19, 23, 32, 33, 36, 38, 43, and 50. Particularlypreferred is at least one pigment selected from the group consisting ofC.I. Pigment Red 122, C.I. Pigment Red 202, and C.I. Pigment Violet 19.

Examples of pigments used for yellow inks include C.I. Pigment Yellow 1,2, 3, 4, 5, 6, 7, 10, 11, 12, 13, 14, 16, 17, 24, 34, 35, 37, 53, 55,65, 73, 74, 75, 81, 83, 93, 94, 95, 97, 98, 99, 108, 109, 110, 113, 114,117, 120, 124, 128, 129, 133, 138, 139, 147, 151, 153, 154, 155, 167,172, 180, 185, and 213. Particularly preferred is at least one pigmentselected from the group consisting of C.I. Pigment Yellow 74, 155, and213. Examples of pigments used for inks of other colors, such as greenand orange, include pigments known in the art.

Pigments other than inorganic pigments preferably have an averageparticle size of 250 nm or less because such pigments are less likely toclog the nozzles and can be more stably ejected. As used herein, theaverage particle size is based on volume. The average particle size canbe measured, for example, by a laser diffraction/scattering particlesize distribution analyzer. The particle size distribution analyzer maybe, for example, a dynamic light scattering particle size distributionanalyzer (e.g., Microtrac UPA available from Nikkiso Co., Ltd.).

1-2. Dye

In this embodiment, dyes can be used as a colorant. Examples of dyesinclude, but not limited to, acid dyes, direct dyes, reactive dyes, andbasic dyes.

The colorant is preferably present in an amount of 0.4% to 12% by mass,more preferably 2% to 5% by mass, based on the total mass (100% by mass)of the ink composition.

2. Resin

Preferred ink compositions that are suitable for use with the ink jetrecording apparatus according to this embodiment and that contain aninorganic pigment include the following compositions:

(1) An ink composition for ink jet recording containing a first resinhaving a heat distortion temperature of 10° C. or lower (hereinafterreferred to as “first ink”); and

(2) An ink composition for ink jet recording containing a second resinand substantially no glycerol (hereinafter referred to as “second ink”).

These ink compositions have the property of easily solidifying on thenozzle surface and the absorbing member and tend to promote damage tothe liquid-repellent film, although this can be effectively prevented bythe ink jet recording apparatus according to this embodiment.

The first ink contains a first resin having a heat distortiontemperature of 10° C. or lower. Such a resin has the property ofstrongly adhering to flexible, absorbent materials such as fabric. Thefirst ink, however, rapidly forms a coating and solidifies, leaving asolid on the nozzle surface and the absorbing member.

The second ink contains substantially no glycerol, which has a boilingpoint of 290° C. at 1 atmosphere. A colored ink containing glyceroldries considerably slowly, which results in noticeable variations inimage density and low ink fixability on various recoding media,particularly recoding media that absorb little or no ink. Because thesecond ink contains no glycerol, the main solvent in the second ink,such as water, volatilizes rapidly, and the proportion of the organicsolvent in the second ink increases accordingly. This lowers the heatdistortion temperature (particularly, the thickening temperature) of theresin and thus promotes solidification of the coating. The second inkpreferably contains substantially no alkylpolyol (excluding glycerol)having a boiling point at 1 atmosphere of 280° C. or higher. In arecording apparatus including a heater that heats a recording mediumtransported to a position opposite the recording head, the second inkdries rapidly near the recording head. Although this could result inmore noticeable problems, they can be effectively prevented by the inkjet recording apparatus according to this embodiment. A heatingtemperature of 30° C. to 80° C. is preferred for high ink storagestability and recording image quality. The heater may be any type ofheater, such as a heat-generating heater, a hot-air heater, or aninfrared heater.

As used herein, the phrase “substantially no” means that glycerol is notpresent in an amount sufficient to make it worthwhile to add glycerol.Quantitatively, glycerol is preferably not present in an amount of 1.0%by mass or more, more preferably 0.5% by mass or more, even morepreferably 0.1% by mass or more, yet even more preferably 0.05% by massor more, further preferably 0.01% by mass or more, most preferably0.001% by mass or more, based on the total mass (100% by mass) of thecolored ink.

The first resin has a heat distortion temperature of 10° C. or lower,preferably −10° C. or lower, more preferably −15° C. or lower. A resinhaving such a heat distortion temperature provides a higher pigmentfixability and thus a higher abrasion resistance on recording media. Theheat distortion temperature is preferably, but not limited to, −50° C.or higher.

The second resin preferably has a heat distortion temperature of 40° C.or higher, more preferably 60° C. or higher. A resin having such a heatdistortion temperature is less likely to clog the head and provides ahigher abrasion resistance on recording media. The heat distortiontemperature is preferably up to 100° C.

As used herein, the term “heat distortion temperature” refers to atemperature value represented as glass transition temperature (Tg) orminimum film-forming temperature (MFT). That is, “heat distortiontemperature of 40° C. or higher” refers to a Tg or MFT of 40° C. orhigher. Preferably, the heat distortion temperature is a temperaturevalue represented as MFT because the redispersibility of the resin canbe more easily evaluated based on MFT than based on Tg. An inkcomposition containing a resin with good redispersibility does notsolidify and is therefore less likely to clog the head.

As used herein, Tg is measured by differential scanning calorimetry. Asused herein, MFT is measured in accordance with ISO 2115:1996 (entitled“Plastics—Polymer dispersions—Determination of white point temperatureand minimum film-forming temperature”).

Examples of resins include, but not limited to, poly(meth)acrylicpolymers such as poly(meth)acrylic acid esters and copolymers thereof,polyacrylonitrile and copolymers thereof, polycyanoacrylates,polyacrylamide, and poly(meth)acrylic acid; polyolefins such aspolyethylene, polypropylene, polybutene, polyisobutylene, polystyrene,copolymers thereof, petroleum resin, cumarone-indene resin, and terpeneresin; vinyl acetate and vinyl alcohol polymers such as polyvinylacetate and copolymers thereof, polyvinyl alcohol, polyvinyl acetal, andpolyvinyl ether; halogen-containing polymers such as polyvinyl chlorideand copolymers thereof, polyvinylidene chloride, fluorocarbon resins,and fluorocarbon rubbers; nitrogen-containing vinyl polymers such aspolyvinylcarbazole, polyvinylpyrrolidone and copolymers thereof,polyvinylpyridine, and polyvinylimidazole; diene polymers such aspolybutadiene and copolymers thereof, polychloroprene, and polyisoprene(butyl rubber); and other resins such as ring-opening polymer resins,condensation polymer resins, and natural polymer resins.

Examples of commercial products of resins include HYTEC E-7025P, HYTECE-2213, HYTEC E-9460, HYTEC E-9015, HYTEC E-4A, HYTEC E-5403P, and HYTECE-8237 (all trade names, available from TOHO Chemical Industry Co.,Ltd.); AQUACER 507, AQUACER 515, and AQUACER 840 (all trade names,available from BYK Japan KK); and JONCRYL 67, 611, 678, 680, and 690(all trade names, available from BASF AG).

Anionic, nonionic, and cationic resins may all be used. In particular,nonionic and anionic resins are preferred because they are suitable foruse with the head. These resins may be used alone or in combination.

The resin is preferably present in an amount of 1% to 30% by mass, morepreferably 1% to 5% by mass, based on the total mass (100% by mass) ofthe ink composition. Such an ink composition forms an image with ahigher gloss and abrasion resistance.

Examples of resins that can be contained in the ink composition includeresin dispersants, resin emulsions, and waxes. In particular, emulsionsare preferred because they provide high adhesion and abrasionresistance.

2-1. Resin Dispersant

The ink composition according to this embodiment may contain a resindispersant so that the pigment contained therein can be stably dispersedin water. If the ink composition contains a pigment dispersed with aresin dispersant such as a water-soluble resin or a water-dispersibleresin (hereinafter referred to as “resin-dispersed pigment”), the resindispersant improves at least one of the adhesion between the inkcomposition and a recording medium and the adhesion between solids inthe ink composition when the ink composition is deposited on therecording medium. In particular, water-soluble resins are preferredbecause they provide high dispersion stability.

2-2. Resin Emulsion

The ink composition according to this embodiment preferably contains aresin emulsion. The resin emulsion forms a resin coating that has theeffect of sufficiently fixing the ink composition to a recording mediumto form an image with high abrasion resistance. This effect allows aprint produced with the ink composition containing the resin emulsion tohave high adhesion and abrasion resistance, particularly on recordingmedia that absorb little or no ink, such as fabric. Although the resinemulsion tends to promote solidification of the inorganic pigment,problems due to solidification can be effectively prevented by the inkjet recording apparatus according to this embodiment.

A resin acting as a binder is preferably added in the form of anemulsion to the ink composition. If a resin acting as a binder is addedin the form of an emulsion to the ink composition, the viscosity of theink composition can be easily controlled to the range suitable for inkjet recording, and the ink composition has high storage stability andejection stability.

Examples of resin emulsions include, but not limited to, homopolymersand copolymers of (meth)acrylic acid, (meth)acrylic acid esters,acrylonitrile, cyanoacrylates, acrylamide, olefins, styrene, vinylacetate, vinyl chloride, vinyl alcohol, vinyl ether, vinylpyrrolidone,vinylpyridine, vinylcarbazole, vinylimidazole, and vinylidene chloride;fluorocarbon resins; and natural resins. Particularly preferred is atleast one of a (meth)acrylic resin and a styrene-(meth)acrylic acidcopolymer resin, more preferably at least one of an acrylic resin and astyrene-acrylic acid copolymer resin, even more preferably astyrene-acrylic acid copolymer resin. The above copolymers may be any ofa random copolymer, a block copolymer, an alternating copolymer, and agraft copolymer.

Commercial products of resin emulsions are also available.Alternatively, a resin emulsion may be prepared, for example, byemulsification polymerization as follows. Specifically, the resin forthe ink composition may be prepared in the form of an emulsion byemulsification polymerization of a monomer of a water-soluble resin asillustrated above in water in the presence of a polymerization catalystand an emulsifier. The polymerization initiator, emulsifier, andmolecular weight modifier used for emulsification polymerization may besimilar to those used in methods known in the art.

The resin emulsion preferably have an average particle size of 5 to 400nm, more preferably 20 to 300 nm. Such a resin emulsion provides ahigher ink storage stability and ejection stability.

The above resin emulsions may be used alone or in combination. The resinemulsion is preferably present in an amount of 0.5% to 15% by mass basedon the total mass (100% by mass) of the ink composition. Such an inkcomposition has a lower solids content and thus has a higher ejectionstability.

2-3. Wax

The ink composition according to this embodiment may contain a wax. Anink composition containing a wax has a higher fixability on recordingmedia that absorb little or no ink. Particularly preferred are emulsionwaxes and suspension waxes. Examples of waxes include, but not limitedto, polyethylene wax, paraffin wax, and polypropylene wax, preferablypolyethylene wax, described below.

An ink composition containing polyethylene wax has high abrasionresistance.

The polyethylene wax preferably has an average particle size of 5 to 400nm, more preferably 50 to 200 nm. Such a polyethylene wax provides ahigher ink storage stability and ejection stability.

The polyethylene wax is preferably present in an amount of 0.1% to 3% bymass (on a solids basis), more preferably 0.3% to 3% by mass, even morepreferably 0.3% to 1.5% by mass, based on the total mass (100% by mass)of the ink composition. Such an ink composition can be effectivelysolidified and fixed to a recording medium and also has a higher inkstorage stability and ejection stability.

3. Defoamer

The ink composition according to this embodiment may contain a defoamer.Specifically, at least one of the ink composition and the impregnationliquid according to this embodiment preferably contains a defoamer. Ifthe ink composition contains a defoamer, it prevents foaming and therebyprevents entry of bubbles into the nozzles.

Examples of defoamers include, but not limited to, silicone defoamers,polyether defoamers, fatty acid ester defoamers, and acetylene glycoldefoamers. In particular, silicone defoamers and acetylene glycoldefoamers are preferred because they are effective in maintaining propersurface tension and interfacial tension and form few bubbles. Thedefoamer preferably has an HLB value based on Griffin's method of 5 orless.

4. Surfactant

The ink composition according to this embodiment may contain asurfactant (other than the defoamers illustrated above, i.e., having anHLB value based on Griffin's method of more than 5). Examples ofsurfactants include, but not limited to, nonionic surfactants. Nonionicsurfactants have the property of uniformly spreading ink over arecording medium. Thus, ink jet recording using an ink containing anonionic surfactant allows the formation of a high-resolution image withlittle bleeding. Examples of nonionic surfactants include, but notlimited to, silicone surfactants, polyoxyethylene alkyl ethersurfactants, polyoxypropylene alkyl ether surfactants, polycyclic phenylether surfactants, sorbitan derivatives, and fluorinated surfactants,preferably silicone surfactants.

Silicone surfactants are more effective in uniformly spreading ink overa recording medium without bleeding than other nonionic surfactants.

Examples of silicone surfactants include, but not limited to,polysiloxanes. Examples of polysiloxanes include, but not limited to,polyether-modified organosiloxanes. Examples of commercial products ofpolyether-modified organosiloxanes include, but not limited to, BYK-306,BYK-307, BYK-333, BYK-341, BYK-345, BYK-346, BYK-348, and BYK-349 (tradenames, available from BYK Japan KK); and KF-351A, KF-352A, KF-353,KF-354L, KF-355A, KF-615A, KF-945, KF-640, KF-642, KF-643, KF-6020,X-22-4515, KF-6011, KF-6012, KF-6015, and KF-6017 (trade names,available from Shin-Etsu Chemical Co., Ltd.).

These surfactants may be used alone or in combination. The surfactant ispreferably present in an amount of 0.1% to 3% by mass based on the totalmass (100% by mass) of the ink composition. Such an ink composition hasa higher ink storage stability and ejection stability.

5. Water

The ink composition according to this embodiment may contain water. Ifthe ink composition is a water-based ink, water is the main solvent andevaporates when a recording medium is heated during ink jet recording.

Examples of water include pure or ultrapure deionized water such as ionexchange water, ultrafiltration water, reverse osmosis water, anddistilled water. The use of water sterilized, for example, byultraviolet irradiation or the addition of hydrogen peroxide preventsgrowth of mold and bacteria during the storage of a pigment dispersionor an ink containing a pigment dispersion for an extended period oftime.

Water may be present in any suitable amount.

6. Organic Solvent

The ink composition according to this embodiment may contain a volatilewater-soluble organic solvent. Examples of organic solvents include, butnot limited to, alcohols and glycols such as ethylene glycol, diethyleneglycol, triethylene glycol, propylene glycol, dipropylene glycol,1,3-propanediol, 1,2-butanediol, 1,2-pentanediol, 1,2-hexanediol,1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, diethylene glycolmono-n-propyl ether, ethylene glycol monoisopropyl ether, diethyleneglycol monoisopropyl ether, ethylene glycol mono-n-butyl ether, ethyleneglycol mono-t-butyl ether, diethylene glycol mono-n-butyl ether,triethylene glycol mono-n-butyl ether, diethylene glycol mono-t-butylether, propylene glycol monomethyl ether, propylene glycol monoethylether, propylene glycol mono-t-butyl ether, propylene glycolmono-n-propyl ether, propylene glycol monoisopropyl ether, propyleneglycol mono-n-butyl ether, dipropylene glycol mono-n-butyl ether,dipropylene glycol mono-n-propyl ether, dipropylene glycol monoisopropylether, diethylene glycol dimethyl ether, diethylene glycol diethylether, diethylene glycol dibutyl ether, diethylene glycol ethyl methylether, diethylene glycol butyl methyl ether, triethylene glycol dimethylether, tetraethylene glycol dimethyl ether, dipropylene glycol dimethylether, dipropylene glycol diethyl ether, tripropylene glycol dimethylether, methanol, ethanol, n-propyl alcohol, isopropyl alcohol,n-butanol, 2-butanol, tert-butanol, isobutanol, n-pentanol, 2-pentanol,3-pentanol, and tert-pentanol; and other organic solvents such asN,N-dimethylformamide, N,N-dimethylacetoamide, 2-pyrrolidone,N-methyl-2-pyrrolidone, 2-oxazolidone, 1,3-dimethyl-2-imidazolidinone,dimethyl sulfoxide, sulfolane, and 1,1,3,3-tetramethylurea.

These organic solvents may be used alone or in combination. The organicsolvent may be present in any suitable amount.

7. pH Adjuster

The ink composition according to this embodiment may contain a pHadjuster. Examples of pH adjusters include inorganic alkalis such assodium hydroxide and potassium hydroxide, ammonia, diethanolamine,triethanolamine, triisopropanolamine, morpholine, potassium dihydrogenphosphate, and disodium hydrogen phosphate.

These pH adjusters may be used alone or in combination. The pH adjustermay be present in any suitable amount.

8. Other Components

In addition to the above components, the ink composition according tothis embodiment may contain materials such as preservatives, fungicides,rust inhibitors, and chelating agents.

9. Method for Manufacturing Ink Composition

The ink composition according to this embodiment can be manufactured bymixing the components (materials) described above together in any order,optionally followed by the removal of impurities, for example, byfiltration. For ease of handling, the pigment is preferably uniformlydispersed in a solvent before mixing.

The materials are preferably mixed together by sequentially adding thematerials to a container equipped with a stirrer, such as a mechanicalstirrer or a magnetic stirrer, and stirring the mixture. The resultingmixture may optionally be filtered, for example, by centrifugation orthrough a filter.

10. Surface Tension of Ink Composition

The surface tension of the ink composition is preferably, but notlimited to, 15 to 35 mN/m. This ensures sufficient permeability of theink composition into the absorbing member and sufficient resistance tobleeding upon recording and thus improves the ink wipeability during thecleaning operation. The surface tension, as described above, may bemeasured using a commonly used surface tension meter (e.g., a CBVP-Zsurface tension meter available from Kyowa Interface Science Co., Ltd.).The difference in surface tension between the ink composition and theimpregnation liquid is preferably 10 mN/m or less. This prevents anextreme decrease in the surface tension of the ink composition when theink composition is mixed with the impregnation liquid near the nozzles.

EXAMPLES

The invention is further illustrated by the following examples andcomparative examples, although these examples are not intended to limitthe invention.

1. Materials for Ink Composition

The main materials for the ink compositions used in the examples andcomparative examples below are as follows:

Colorants: C.I. Pigment Blue 15:3 (with an average particle size of 100nm and a Mohs hardness of 1 or less), C.I. Pigment Red 122 (with anaverage particle size of 120 nm and a Mohs hardness of 1 or less),rutile-type titanium dioxide (with an average particle size of 200 nmand a Mohs hardness of 7.2), rutile-type titanium dioxide (with anaverage particle size of 330 nm and a Mohs hardness of 7.2), andrutile-type titanium dioxide (with an average particle size of 450 nmand a Mohs hardness of 7.2)

Organic solvents: 1,2-hexanediol, 2-pyrrolidone, and propylene glycol

Resin emulsion: styrene-acrylic acid copolymer resin emulsion (with a Tgof 85° C. and an average particle size of 140 nm)

Polyethylene wax: AQUACER 515 (trade name, available from BYK Japan KK)

Silicone surfactant: BYK 348 (trade name, available from BYK Japan KK)

Acetylene glycol defoamer: Surfynol DF110D (trade name, available fromNissin Chemical Industry Co., Ltd., HLB=3) pH adjuster: triethanolamine

The average particle size was measured by a Microtrac UPA available fromNikkiso Co., Ltd. The Tg was measured by a DSC-6200R available from SIINanoTechnology Inc. using a sample prepared by drying the emulsion.

2. Preparation of Pigment Dispersion for Ink Composition

To a mixture of 7 parts by mass of potassium hydroxide, 23 parts by massof water, and 30 parts by mass of triethylene glycol mono-n-butyl etherwas added 40 parts by mass of a water-soluble resin (copolymer ofmethacrylic acid, butyl acrylate, styrene, and hydroxyethyl acrylate ina mass ratio of 25:50:15:10 with a weight average molecular weight of12,000). The mixture was heated at 80° C. with stirring to prepare anaqueous resin solution.

Then, 3.0 kg of a colorant and 10.25 kg of water were added to andpremixed with 1.75 kg of the aqueous resin solution (43% solids) withstirring by an agitator to obtain a mixed solution. The mixed solutionwas dispersed by passing it multiple times through a horizontal beadmill equipped with a multi-disk impeller, having an effective volume of1.5 L, and charged with 85% of 0.5 mm zirconia beads. Specifically, themixed solution was dispersed by passing it twice through the bead millat a bead speed of 8 m/s and a discharge rate of 30 L/h to obtain apigment-dispersed mixed solution having an average particle size of 325nm. The pigment-dispersed mixed solution was then subjected tocirculation dispersion in a horizontal annular bead mill having aneffective volume of 1.5 L and charged with 95% of 0.05 mm zirconiabeads. Specifically, 10 kg of the pigment-dispersed mixed solution wasdispersed using a 0.015 mm screen at a bead speed of 10 m/s and acirculation rate of 300 L/h for 4 hours to obtain a water-based pigmentdispersion containing 20% of the colorant solids and 5% of thewater-soluble resin.

3. Preparation of Ink Composition

The resulting pigment dispersions were weighed such that the colorantwas to be present in the amount shown in Table 1. To the pigmentdispersions, the components other than the colorants shown in Table 1below were added in the amounts (% by mass) shown in Table 1 below(100.0% by mass in total) to prepare ink compositions. Each inkcomposition was prepared by placing the individual components in acontainer, stirring the mixture with a magnetic stirrer for 2 hours, andfiltering the mixture through a membrane filter with a pore size of 5 μmto remove foreign matter (impurities) such as dust and coarse particles.The water-soluble resin was present in the ink compositions in an amountequal to one fourth the amount of colorant.

TABLE 1 Type of material Name of material C M W1 W2 W3 W4 Pigment PB15:3 (100 nm, with Mohs 2.5 hardness of 1 or less) PR 122 (120 nm, withMohs 2.5 hardness of 1 or less) Rutile-type titanium dioxide (200 nm, 10with Mohs hardness of 7.2) Rutile-type titanium dioxide (330 nm, 10 25with Mohs hardness of 7.2) Rutile-type titanium dioxide (450 nm, 10 withMohs hardness of 7.2) Organic 1,2-Hexanediol 5 5 5 5 5 5 solvent2-Pyrrolidone 15 15 15 15 15 15 Propylene glycol 10 10 10 10 10 10 ResinResin emulsion 1 1 1 1 1 1 Polyethylene wax 0.5 0.5 0.5 0.5 0.5 0.5Surfactant Silicone surfactant 0.5 0.5 0.5 0.5 0.5 0.5 DefoamerAcetylene glycol defoamer 0.2 0.2 0.2 0.2 0.2 0.2 pH adjusterTriethanolamine 0.2 0.2 0.2 0.2 0.2 0.2 Water Pure water Balance BalanceBalance Balance Balance Balance Total 100 100 100 100 100 100

4. Materials for Impregnation Liquid

The main materials for the impregnation liquid used in the examples andcomparative examples below are as follows:

Penetrant: acetylene glycol surfactant (Olfine E1010 available fromNissin Chemical Industry Co., Ltd.)

Humectant: polyethylene glycol (with a weight average molecular weightof 200)

5. Preparation of Impregnation Liquid

The components shown in Table 2 below were mixed in the amounts (% bymass) shown in Table 2 below (100.0% by mass in total) to prepare animpregnation liquid. The impregnation liquid was prepared by placing theindividual components in a container, stirring the mixture with amagnetic stirrer for 2 hours, and filtering the mixture through amembrane filter with a pore size of 5 μm to remove foreign matter(impurities) such as dust and coarse particles. The surface tension wasmeasured by the Wilhelmy method at a liquid temperature of 25° C. usinga surface tension meter (e.g., a CBVP-Z surface tension meter availablefrom Kyowa Interface Science Co., Ltd.).

TABLE 2 Content Type of material Name of material (% by mass) PenetrantAcetylene glycol surfactant 10 Humectant Polyethylene glycol (withweight 90 average molecular weight of 200) Surface tension (mN/m) 39.6

6. Ink Jet Recording

A modified PX-H10000 printer (available from Seiko Epson Corporation)was used (hereinafter referred to as “modified PX-H10000”). The printerwas modified by mounting a print head including a silicon nozzle platewith a liquid-repellent film and a nozzle plate cover as shown in FIG.5A, an absorbing member, an elastic member, and an actuating mechanism.

The silicon nozzle plate was made of single-crystal silicon. A siliconoxide film (SiO₂ film) was deposited on the nozzle surface of thesilicon nozzle plate by chemical vapor deposition (CVD), in which SiCl₄and steam were introduced into a CVD reactor. The SiO₂ film had athickness of 50 nm. Following oxygen plasma treatment, aliquid-repellent film (with a thickness of 10 nm) was deposited on theSiO₂ film by CVD using C₈F₁₇C₂H₄SiCl₃ to fabricate a silicon nozzleplate with a liquid-repellent film.

The absorbing member was made of nonwoven cupra (with a density of 0.01(g/cm²) and a thickness of 0.4 mm). The elastic member was a roller witha Shore A hardness of 30. The Shore A hardness was measured by ameasurement method in accordance with ATSM D-2240 using a sheet sampleprepared by pressing the outer layer of a foam roller or an unfoamedthermoplastic elastomer at a temperature of 200° C. In the examples andcomparative examples, the impregnation liquid was present in an amountof 40% by mass based on 100% by mass of the absorbing member.

The actuating mechanism was configured to bring the absorbing memberinto contact with the nozzle surface of the recording head by pressingthe side of the absorbing member facing away from the nozzle surfacewith the pressing member therebetween under a predetermined load and tomove the absorbing member and the recording head relative to each otherto perform a cleaning operation in which the ink composition was removedfrom the nozzle surface with the absorbing member.

7. Examples 1 to 5 and Comparative Examples 1 and 2, Reference Example 1and 2 7-1. Cleaning Performance Test

The modified PX-H10000 was used to print the ink compositions shown inTable 1 for 20 minutes, followed by a cleaning operation as shown inTable 3. This cycle was repeated 50 times. Thereafter, the nozzlesurface was visually inspected for ink build-up. FIG. 4 is a referenceview illustrating ink build-up.

A: The width of ink build-up was 0.1 mm or less.

B: The width of ink build-up was more than 0.1 mm and not more than 0.3mm.

C: The width of ink build-up was more than 0.3 mm and not more than 0.6mm.

D: The width of ink build-up was more than 0.6 mm.

7-2. Liquid-Repellent Film Conservation Test

The modified PX-H10000 was used to perform a suction operation in whichink was removed from the head using a suction pump, followed by acleaning operation as shown in Table 3. This cycle was repeated 12,000times. Thereafter, the liquid-repellent film was examined near thenozzles under a light microscope (HISOMET-II DH2 high-precisionnon-contact depth measuring microscope available from Union Optical Co.,Ltd.).

A: The liquid-repellent film showed substantially no peeling.

B: The liquid-repellent film peeled slightly and discolored, although itdid not affect ejection.

C: The liquid-repellent film peeled at the edges of the nozzles, and itaffected ejection.

D: The liquid-repellent film peeled over the entire nozzle surface, andit significantly affected ejection.

TABLE 3 Comparative Comparative Reference Reference Example 1 Example 2Example 3 Example 4 Example 5 Example 1 Example 2 Example 1 Example 2Impregnation  1  1  1  1  1 None  1 None None liquid Composition Ink W1W2 W3 W1 W1 W1 W4 C M composition Thickness of 10 10 10 10 10 10 10 1010 liquid- repellent film (nm) Material for Silicon Silicon SiliconSilicon Silicon Silicon Silicon Silicon Silicon nozzle plate Shore A 3030 30 30 30 30 30 30 30 hardness of roller Load (gf) 300  300  300  500 200  300  300  300  300  Cleaning Cupra Cupra Cupra Cupra Cupra CupraCupra Cupra Cupra member

TABLE 4 Comparative Comparative Reference Reference Example 1 Example 2Example 3 Example 4 Example 5 Example 1 Example 2 Example 1 Example 2Cleaning B A A A B A A performance Conservation A A B B A C C A A ofliquid- repellent film

The above results demonstrate that the absence of the impregnationliquid results in poor conservation of the liquid-repellent film(Comparative Example 1). The results also demonstrate that the use of anink composition containing more than 20% by mass of an inorganic pigmentresults in poor conservation of the liquid-repellent film (ComparativeExample 2). In contrast, the results revealed that ink jet recordingapparatuses according to embodiments of the invention (Examples 1 to 5)allow both high cleaning performance and good conservation of theliquid-repellent film. The results also demonstrate that the use of anink composition containing an organic pigment with low Mohs hardness,rather than an inorganic pigment, results in good conservation of theliquid-repellent film even if an absorbing member containing noimpregnation liquid is used (Reference Examples 1 and 2).

1. An ink jet recording apparatus comprising: a recording head having aplurality of nozzles through which an ink composition containing aninorganic pigment is ejected, a nozzle surface having nozzle orifices,and a liquid-repellent film disposed on the nozzle surface; an absorbingmember that absorbs the ink composition containing the inorganic pigmentfrom the nozzle orifices and the nozzle surface; an actuating mechanismincluding a pressing member that presses the absorbing member and thenozzle surface relative to each other; and an elastic member that coversthe pressing member and that has a Shore A hardness of 10 to 60, whereinthe actuating mechanism moves at least one of the absorbing member andthe recording head relative to the other to perform a cleaning operationin which the ink composition is removed from the nozzle surface with theabsorbing member, the absorbing member contains an impregnation liquidduring the cleaning operation, and the inorganic pigment is present inthe ink composition in an amount of 20% by mass or less and has a Mohshardness of more than 2.0 and an average particle size of 200 nm ormore.
 2. The ink jet recording apparatus according to claim 1, whereinthe impregnation liquid has a surface tension of 45 mN/m or less.
 3. Theink jet recording apparatus according to claim 1, wherein the pressingmember presses the absorbing member containing the impregnation liquidagainst the nozzle surface with a force of 50 to 500 gf.
 4. The ink jetrecording apparatus according to claim 1, wherein the actuatingmechanism moves at least one of the absorbing member and the recordinghead relative to the other at a speed of 1 to 10 cm/s.
 5. The ink jetrecording apparatus according to claim 1, wherein the recording headfurther has a nozzle plate cover that at least partially covers thenozzle surface; and the absorbing member is a fabric.
 6. The ink jetrecording apparatus according to claim 1, wherein the absorbing memberhas a thickness of 0.1 to 3 mm.
 7. The ink jet recording apparatusaccording to claim 1, wherein the ink composition further contains aresin emulsion.
 8. The ink jet recording apparatus according to claim 1,wherein the nozzle surface has a first row of nozzles through which theink composition containing the inorganic pigment is ejected and a secondrow of nozzles through which an ink composition containing a colorantother than the inorganic pigment is ejected, and the actuating mechanismmoves at least one of the absorbing member and the recording headrelative to the other in a direction in which the nozzles are arranged.